Hot melt calendered or extruded wear layer for embossed substrates and method of manufacture

ABSTRACT

The invention relates to a textured surface covering having a hot melt wear layer and methods of applying the hot melt wear layer to a textured or embossed surface without distortion of the visual image of the textured substrate. The wear layer substantially follows the contours of the substrate with minimum change in thickness of the wear layer over the textured surface and provides an aesthetically pleasing three dimensional appearance to the textured surface of the substrate. Melt applying the melt processable polymer resin to the textured substrate with a conformable pressure roll deter entrapment of bubbles between the wear layer and the textured substrate. Therefore, the wear layer exhibits significant clarity and visual depth, as well as improved maintenance (cleanability) properties. The resulting product has a visual image clarity reflecting any texture in the substrate including very light reflective (lenticular moray) embossings.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a division of co-pending U.S. applicationSer. No. 09/200,813, filed Nov. 27, 1998.

FIELD OF THE INVENTION

The present invention relates to decorative products that are suitableas surface coverings for floors, walls, etc., and, more particularly itis directed to an embossed or textured product having a wear layer witha substantially uniform thickness and the method of manufacturing thewear layer. The wear layer is applied to an embossed or texturedsubstrate and uniquely follows the contours of the substrate to providea unique three dimensional aesthetic appearance with enhanced clarity.

HISTORICAL BACKGROUND OF THE INVENTION

Decorative products useful as surface coverings for floors, walls, etc.,are well known in the art and have achieved broad use in domestic andcommercial environments. Unfortunately, the application of a protectivesurface layer on an embossed substrate has presented many difficultproblems. The embossing tends to diminish or distort upon application ofthe wear layer. Such distortion or diminishing reduces the aestheticappearance and the three dimensional effect desired. Further, air isentrapped between the wear layer and embossed or textured substrate whenthe wear layer is laminated to an embossed or textured substrate byconventional lamination processes.

Many prior art protective wear layer surfaces comprise relatively rigidthermoset polymers which are laminated to a flat substrate. Thelaminated wear layer and substrate is then embossed. For example, SawkaU.S. Pat. No. 5,405,675 discloses applying a substantially uniformlythick protective surface layer to a base layer or substrate and thenembossing the base layer at a temperature between the softeningtemperature of the base layer and the decomposition temperature of thebase layer, but less than the softening temperature of the wear layer.

Attention is also called to Fry U.S. Pat. No. 4,614,556. In this patentthe wear layer has a relief pattern formed thereon and is laminated to aflat base layer. In another embodiment, the wear layer, which issubstantially uniform in thickness, is embossed and then the base layercomprising a hot-melt composition is applied to the embossed wear layer.

Other commercially available floor structures are made by applying aliquid plastisol to a smooth or textured substrate. When the plastisolis fused, air bubbles are entrapped reducing clarity. Further, theliquid plastisol tends to flow into the depressions of the embossedsubstrate, reducing the texture of the exposed surface.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of this invention to provide a decorative surfacecovering for floors, walls, etc., which has a subtle textured appearanceproviding new visual and physical three dimensional properties withenhanced clarity.

Another object of this invention is to provide a textured product whichvisually retains all of the textured features of the substrate whileproviding protection by means of the wear layer.

Still another object of this invention is to provide a wear layer on anembossed or textured substrate which is substantially uniform inthickness with substantially no variation in wear layer thicknessthroughout its length and breadth.

Yet a further object of this invention is to provide a textured productwhich clearly reflects the texture of the substrate including finelenticular embossing.

Still a further object of this invention is to provide a direct hot meltcalendering process or an indirect hot melt calender process in which amelt processable polymer resin or hot melt calendered film is formed andapplied to woven fabrics, burlap, fibers, caning and scrims that havetextured properties without evidence of detrimental air entrapment whileretaining a visual image of the textured material.

A further object of this invention is to provide a hot melt calenderingprocess and wear layer which can be applied to a textured substratewithout shade change which normally occurs with plastisol wetting out afabric or paper substrate.

Still a further object of this invention is to provide a unique texturedmaterial and method of producing the same which can be readilymanufactured with commercially available calendering equipment.

Another object of this invention is the application of a hot melt wearlayer to the textured or embossed substrate without loss of sharpnessand distinctiveness and the softening of the embossed substrate whichcan cause a deterioration of the embossed pattern.

Yet another object of this invention is to permit pre-embossing(chemically and/or mechanically) of a substrate prior to applying a wearlayer, which allows for a range of additional decorating techniques.

In summary, this invention relates to a hot melt calendered or extrudedwear layer which can be melt applied to an embossed or texturedsubstrate without distorting the substrate and which wear layer conformsto the embossing or texture to give a three dimensional aestheticallypleasing product.

These and other objects of the invention will be apparent from thefollowing description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of one preferred embodiment of theequipment and process of the present invention.

FIG. 2 is a schematic representation of a second preferred embodiment ofthe equipment and process of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In general, this invention relates to the unique combination of visualand physical properties achieved by applying a hot melt calendered orextruded PVC or non-PVC wear layer to a textured substrate.

Typical applications of this technology are floor and wall coveringproducts.

A variety of textured substrates have been used such as, but not limitedto, woven fabrics, burlap, duck, linens, decorative papers, fibers,scrims, caning and various types of embossed vinyl or embossed foams.The embossed vinyl or foam can be created either chemically and/ormechanically. These textured substrates can also be decorated viagravure printing, screen printing, spray printing or other means toenhance the decorative image.

The melt processable layer can be formed and applied via melt calenderequipment in widths limited only by equipment and substrateavailability. Referring to FIG. 1, a melt processable polymer resincomposition 1 is delivered as a molten extrudate to a three rollcalender 2 between first roll 3 and second roll 4. The melt processablepolymer resin composition is further softened in the three roll calenderby the heated rolls. The thickness of the molten layer 5 is determinedby the gap between the second roll 4 and the third roll 6.

An embossed or textured substrate 7 is preheated by a heater 8. Themolten layer 5 is applied to the preheated substrate 7 between the thirdroll 6 and the conformable pressure roll 9 forming textured multilayeredcomposite 10 in which the melt processable polymer resin compositionforms a substantially uniformly thick wear layer. The conformablepressure roll deters air entrapment between the melt processable polymerresin composition and the textured substrate. The exposed surface of thewear layer closely follows the embossing or texture of the substrate.

Referring to FIG. 2, an indirect process is shown in which the hot meltcomposition or melt processable polymer resin is introduced as a film11. The film 11 is subsequently melted or softened and applied to thesubstrate with a calender, including a two roll calender, or heated drumand conformable pressure roll, such as a rubber roll.

In FIG. 2, the film 11 is introduced to a conformable rubber pressureroll 12 and onto a heated drum 13 in such a manner to eliminateentrapment of air between the film 11 and drum 13. The film is heated bythe drum to melt the film or a softened condition approaching melt. Thetextured substrate 14 is preheated by heater 15. The film is then meltapplied to the preheated substrate 14 between the heated drum 13 and asecond rubber pressure roll 16 forming textured multilayered composite17.

The melt calendered layer can have a wide range of thickness dependingon cost and performance capabilities desired. Typical thickness mayrange from a few mils (0.005″) to very thick layers (0.050″ or greater).The thickness of the layer varies less than 25% with a preferredvariation of less than 20%. The difference in height of the pre-texturedsurface of the present invention is at least about 1 mil verticaldistance in not more than 20 mils horizontal distance, preferably atleast about 2 mils vertical distance in not more than 20 mils horizontaldistance, and the more preferably at least about 5 mils verticaldistance in not more than 20 mils horizontal distance.

The average thickness of the overlying wear layer is between about 2mils to about 50 mils. The preferred thickness is between about 5 milsto about 30 mils, and the most preferred is between about 10 mils toabout 20 mils.

Melt calendering a melt processable layer directly to the texturedsubstrate can be achieved without the air entrapment normally associatedwith lamination of a transparent layer onto an embossed or texturedsubstrate by use of a conformable, preferably rubber, pressure roll.

Adhesive coatings may need to be applied to some substrates in order toprovide adequate adhesion of the composite layers.

It has been determined that there are critical aspects to this inventionrelating to the viscosity of the hot melt calendered wear layer. Theviscosity must be within a range of 4,500 to 70,000 poise. Above 70,000poise the applied hot melt wear layer will not adhere adequately to thesubstrate and the temperature necessary for the viscosity to be below4,500 poise will cause the hot melt film composition to degrade. Theviscosity is measured on an Instron Capillary Rheometer with a ram speedof 0.5 inches per minute and the 0.9960 inch long, 0.5033 inch diametercapillary or a shear rate of 73 per second.

For typical melt processable compositions, the specified viscosity rangecorresponds to a temperature range of 425° F. to 225° F. The preferredrange is 10,000 to 50,000 poise (375° F. to 295° F.). In this range themelt composition bonds well to the substrate and it flows to conformwell to the embossed substrate while substantially maintaining a uniformthickness. The most preferred range is 13,000 to 24,000 poise whichcorresponds to 325° F. to 360° F. The applied hot melt composition coolsrapidly on the substrate avoiding distortion of the substrate resinthough the melt temperature of the substrate may be similar to that ofthe hot melt composition which is applied.

The pre-textured substrate may comprise a layer of a woven fibrouslayer, or a non-woven fibrous layer, or an embossed layer, or a layercomprising deposited matter and combinations thereof, such as a foamableink or non-foamable ink. In any case, the temperature of distortion ormelt of the pre-textured resin substrate need not be greater than thatof the melt processable composition applied thereto. The viscosity ofthe melt processable composition is critical. The viscosity and thetemperature associated therewith and rapid cooling permit the wear layerto conform to the textured substrate without it flowing around and intothe valleys of the embossed substrate to give a substantially uniformwear coat thickness over the substrate without distortion of thetextured surface.

A typical melt processable polymer resin having the followingformulation was dryblended and compounded in an extruder, achieving amelt at 350° F. to 380° F.

Ingredient Weight Percent General Purpose Vinyl 66.5 Chloride ResinMethylmethacrylate/Acrylic 1.3 Copolymer Processing Aid Acrylic ReleaseAgent 0.3 Methylmethacrylate/Acrylic 3.3 Copolymer Impact Modifier FattyAcid Ester Lubricant 0.3 Plasticizer 26.0 Stabilizer 2.3

This melt was introduced into a three roll calender with the firstcalender roll at about 335° F., the second calender roll at about 345°F. and the third calender roll at about 355° F.

A molten layer, nominally 15 mils thick, was formed and applied directlyto a textured substrate between the third calender roll and a rubberpressure roll. The textured substrate was preheated to about 275° F. Asecond textured multilayer composite was made using the same procedurebut with a nominally 20 mil thick molten layer.

Alternatively, a commercially available, 20 mil thick flexible polyvinylchloride film was substituted for the melt processable polymer resincomposition formed above. The film was heated around a drum, to atemperature of about 345° F.

In both cases, the melt processable polymer resin wear layer had asubstantially uniform thickness with a variation of less than 25% whichfollowed the contours of the pre-textured substrate. The wear layer wasin intimate contact with the pre-textured substrate; there were novisible bubbles entrapped between the wear layer and the adjacentsurface of the pre-textured substrate, even when the difference inheight of the pre-textured surface was at least about 5 mils verticaldistance over no more than about 20 mils horizontal distance.

While this invention has been described as having a preferred design, itis understood that it is capable of further modifications, and usesand/or adaptations of the invention and following in general theprinciple of the invention and including such departures from thepresent disclosure as come within the known or customary practice in theart to which the invention pertains, and as may be applied to thecentral features hereinbefore set forth, and fall within the scope ofthe invention or limits of the claims appended hereto.

What is claimed is:
 1. A method of manufacturing a floor or wallcovering having a wear layer bonded thereto comprising the steps of: a)heating a melt processable polymer resin composition to melt or softenthe polymer resin composition; b) applying the melted or softened meltprocessable polymer resin composition to a pre-textured surface of asubstrate, the pre-textured surface having an area with a difference inheight of at least about 1 mil vertical distance over no more than about20 mils horizontal distance; and c) cooling the melt processable polymerresin composition after it is applied to the pre-textured surface toform a textured surface covering for floor or walls comprising a wearlayer bonded well on the pre-textured substrate, the wear layer havingan average thickness of between about 2 mils to about 50 mils, theexposed surface of the wear layer closely follows the textured surfaceof the substrate, wherein the wear layer is of substantially uniformthickness.
 2. The method of claim 1, wherein the melt processablepolymer resin composition is applied to the pre-textured substratebetween a heated roll. or drum and a conformable. pressure.
 3. Themethod of claim 2, wherein the melt processable polymer resincomposition is formed into an ambient temperature film prior to beingheated on the roll or drum.
 4. The method of claim 1, wherein the meltprocessable polymer resin composition is formed into a layer in acalendar prior to being applied to the pre-textured surface of thesubstrate.
 5. The method of claim 1, wherein the melt processablepolymer resin composition is heated in an extruder.
 6. The method ofclaim 1, wherein the average thickness of the wear layer is greater than10 mils.
 7. The method of claim 1, wherein the average thickness of saidwear layer is between about 5 mils to about 50 mils.
 8. The method ofclaim 7, wherein the average thickness of said wear layer is betweenabout 10 mils to about 20 mils.
 9. The method of claim 8, wherein thedifference in height is at least about 2 mil vertical distance over nomore than about 20 mils horizontal distance.
 10. The method of claim 9,wherein the difference in height is at least about 5 mil verticaldistance over no more than about 20 mils horizontal distance.
 11. Themethod of claim 1, wherein the pre-textured surface is heated prior tothe application of the wear layer composition.
 12. The method of claim1, wherein the melt processable polymer resin composition is heated onthe roll of a calender.
 13. The method of claim 1, wherein thepre-textured surface comprises fibrous matter.
 14. The method of claim1, wherein the pre-textured surface comprises deposited matter.
 15. Themethod of claim 14, wherein the deposited matter is incompressibleduring application of the melted or softened polymer resin composition.16. A method of manufacturing a textured surface covering having a wearlayer bonded thereto comprising the steps of: a) heating a meltprocessable polymer resin composition to melt or soften the polymerresin composition; b) applying the melted or softened melt processablepolymer resin composition to a pre-textured surface of a substrate, thepre-textured surface. having an area with a difference in height of atleast about 1 mil vertical distance over no more than about 20 milshorizontal distance; and c) cooling the melt processable polymer resincomposition after it is applied to the pre-textured surface to form atextured surface covering for floor or walls comprising a wear layerbonded well on the pre-textured substrate, the wear layer having anaverage thickness of between about 2 mils to about 50 mils, wherein themelt processable polymer resin composition is applied to thepre-textured substrate between a heated roll or drum and a conformablepressure roll, and wherein the melt processable polymer resincomposition is heated on the roll or drum, prior to being applied to thetextured substrate. and wherein the exposed surface of the wear layerclosely follows the textured surface of the substrate wherein the wearlayer is of substantially uniform thickness.
 17. The method ofmanufacturing a textured surface covering according to claim 16, whereinthe melt processable polymer resin composition is formed into a layer ina calender prior to being applied to the pre-textured surface of thesubstrate.
 18. The method of manufacturing a textured surface coveringaccording to claim 16, wherein the melt processable polymer resincomposition is heated in an extruder.
 19. The method of manufacturing atextured surface covering according to claim 16, wherein the averagethickness of the wear layer is greater 10 mils.
 20. The method ofmanufacturing a textured surface covering according to claim 16, whereinthe average thickness of said wear layer is between about 5 mils toabout 50 mils.
 21. The method of manufacturing a textured surfacecovering according to claim 20, wherein the average thickness of saidwear layer is between about 10 mils to about 20 mils.
 22. The method ofmanufacturing a textured surface coverage according to claim 16, whereinthe pre-textured surface is heated prior to the application to the wearlayer composition.
 23. The method of manufacturing a textured surfacecovering according to claim 16, wherein the melt processable polymerresin composition is heated on the roll of a calender.
 24. The method ofmanufacturing a textured surface covering according to claim 16, whereinthe melt processable polymer resin composition is formed onto an ambienttemperature film prior to being heated on the roll or drum.
 25. Themethod of manufacturing a textured surface covering according to claim16, wherein the pre-textured surface comprises fibrous matter.
 26. Themethod of manufacturing a textured surface covering according to claim16, wherein the pre-textured surface comprises deposited matter.
 27. Themethod of manufacturing a textured surface covering according to claim26, wherein the deposited matter is incompressible during application ofthe melted or softened polymer resin composition.
 28. A method ofmanufacturing a textured surface covering having a wear layer bondedthereto comprising the steps of: a) heating a melt processable polymerresin composition to melt or soften the polymer resin composition; b)applying the melted or softened melt processable polymer resincomposition to a pre-textured surface of a substrate, the pre-texturedsurface having an area with a difference in height of at least about 1mil vertical distance over no more than about 20 mils horizontaldistance; and c) cooling the melt processable polymer resin compositionafter it is applied to the pre-textured surface to form a texturedsurface covering for floor or walls comprising a wear layer bonded wellon the pre-textured substrate, the wear layer having an averagethickness of between about 2 mils to about 50 mils, wherein the meltprocessable polymer resin composition comprises a PVC resin and whereinthe exposed surface of the wear layer closely follows the texturedsurface of the substrate, wherein the wear layer is of substantiallyuniform thickness.